ELECTRICAL SYSTEM
I. Test the signal generator and the ignition coil
as described
in
this chapler before performing this
test.
If either
of
these units arc faulty, this lest will
n.ot
pr
ov
id
e any usable tcst result
s.
2.
Test
th
e
ignilO
r's
un
it
ability to produce a spark.
Perfo
rm
the
fo
llowing:
a. Remove the spark plug from the cylinder as
described
in
Chapter Three.
b.
Connect the spark plug wire
and
connector to
the
spark pl
ug
and
l
ouc
h the
spa
rk plug's
base
to a good ground such as the cngine cylinder
head (
Figur
e
18
). Make sure the spark plug
is
against bare metal. not a painted surface.
Position the spark plug so
yo
u can sec the
electrodes.
WARNI
NG
If
if
is necessary
10
hold the high
I'o/rage lead, do so with an insulated
pair
of
pliers. The high I'oltage
generated
by
the signal generator
couM produce serious
or
fatal shocks.
c.
Turn the engine
ove
r with the starter.
If
a
fat
blue spark occurs the ignition unit is
in
good
co
ndition.
d.
If
a weak spark
or
no spark
is
obtained and
the signal generator and ignition coil are okay,
ha
ve
the
ig
nit
or
unit tested
by
a Suzuki dealer.
e. Reinsta
ll
the spark plug and co
nn
ect the high
vo
ltage lead to the spark plug.
3.
If
all
of
the ignition components are o
ka
y.
then
check the
fo
llowing:
a. C
he
ck
for
an open or short in the wire harness
between each component in the system.
b.
Aga in. ma
ke
sure all connections between the
va
rious compone
nt
s are clean and tight. Be
sure that the wiring connectors are pushed
together
fi
rmly to help keep out moisture.
Ignitor Unit
Replace
ment
1.
Remove the seat as described
in
Chapter
Twelve.
2. Remo
ve
the left-hand frame cover.
3.
Disco
nn
ect the ba
tt
ery negative lead (Figure 9).
4. Carefully
pu
ll
the ignitor unit and its rubber
mount (
B.
Figure
17
) from the mounting tab on
the frame.
219
5. Di
sconnec
t the ignition unit's electrical
co
nnector (A.
Figure
17
).
6.
Remove the ignitor
un
il.
7.
Attach the elect
ri
cal connector to the unit. Make
s
ur
e the electrical connector
is
free
of
corrosion
and is
ti
ght.
8.
Insta
ll
a new ignitor unit onto the frame.
9.
Connect the battery negative lead.
10.
In
stall the left-hand frame cover.
11.
In
sta
ll
the seat as de
sc
ribed
in
Chapter Twelve.
STARTING SYSTEM
Th
e sta
rt
er system includes an ignition switch.
a
st
arl
er
switch.
cl
ut
ch i
nt
erlock switch. sidestand
interlock switch (1987-1988 models). automatic
decom
pr
ession contr
ol
unit .
Sla
rt
er solenoid,
battery and starter motor as shown
in
(
Figur
e
21
).
Each
co
mponent
of
this system
is
covered
se
parately
in
this chapter except for the battery that
is
covered in Chapter
Thr
ee.
ELECTRIC
STARTER
Removal/Installation
1.
Remove the seat as described
in
Chapter
Twelve.
2. Remove the left-hand frame cover.
3.
Disconnect
th
e battery negati
ve
lead (
Figure
9).
4. Slide back the rubber boot (A.
Figure
22) on
the electrical cable connector.
5.
Disconnect the starter electrical cable from the
starter.
6.
Re
mov
e the bolts securing the starter (B, Figure
22) to the crankcase.
7.
Lift up the r
ig
ht-hand end of the start
er
a
nd
wi
thdraw
it
from the top of the
cr
ankcase.
8.
In
stall
by
reversi
ng
these rem
ova
l step
s.
Note
the
fo
ll
owing during installation.
9. Make sure the O-ring seal (A.
Figur
e 23) is
in
good condition and
is
in
place on the left-hand end
of
the starter.
10
. Make sure the electrical co
nn
ector is free
of
corrosion a
nd
is
tight.
Pre
l
iminary
Inspection
The overhaul of a starter motor
is
best le
ft
to an
expert. Th
is
procedure shows how to detect a
defective starte
r.
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